Intake Manifold: Installation

Install the intake manifold onto cylinder heads.
NOTE: Use a new gasket.

Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 1: Identifying Intake Manifold Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Connect the fuel delivery hose, fuel return hose, and evaporation hose. Refer to INSTALLATION , Fuel Delivery, Return and Evaporation Lines .
NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

Fig 2: Identifying Fuel Delivery, Fuel Return And Evaporation Hoses
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Connect the connector to the oil flow control solenoid valve.

Fig 3: Identifying Oil Flow Control Solenoid Valve Connector
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Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).

Fig 4: Identifying Engine Coolant Temperature Sensor, Oil Pressure Switch And Crankshaft Position Sensor
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Connect the connector to the knock sensor.

Fig 5: Identifying Knock Sensor Connector
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Connect the connector to the power steering pump switch.

Fig 6: Identifying Power Steering Pump Switch Connector
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Connect the connectors to camshaft position sensor.

Fig 7: Identifying Camshaft Position Sensor Connector
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Connect the connector to the secondary air combination valve.

Fig 8: Identifying Secondary Air Combination Valve Connector
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Install the engine harness with clip (A) to the rocker cover.

Fig 9: Identifying Engine Harness Clip
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Connect the connector to the ignition coil.

Fig 10: Locating Ignition Coil Connector
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Connect the air duct to the secondary air pump, and install the air duct on the rocker cover.
Tightening torque:

9 N.m (0.9 kgf-m, 6.6 ft-lb)

Fig 11: Locating Air Duct With Bolt
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Connect the engine harness connectors to the bulkhead harness connectors.

Fig 12: Identifying Engine Harness Connectors
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Connect the air control hose (A) to the waste-gate actuator, and tighten the clamp that holds the intake duct on the turbocharger.
Tightening torque:

3 N.m (0.3 kgf-m, 2.2 ft-lb)

Fig 13: Identifying Air Control Hose With Bolt
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Connect the brake booster vacuum hose.

Fig 14: Identifying Brake Booster Vacuum Hose
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Connect the PCV hose to the rocker cover.
NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS

Fig 15: Identifying PCV Hose Clamp
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Connect the engine coolant hoses to throttle body.

Fig 16: Identifying Engine Coolant Hoses
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Install the duct to the throttle body.
Tightening torque:

3 N.m (0.3 kgf-m, 2.2 ft-lb)
Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 17: Locating Air By-Pass Pipe Bolts
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Attach the connector to the PCV hose assembly.

Fig 18: Identifying PCV Hose Assembly Connector
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Connect the vacuum hose (A) and the connector (B) to the PCV hose assembly.

Fig 19: Identifying Vacuum Hose And Connector
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Install the A/C pressure hoses. Refer to INSTALLATION , Hose and Pipe .
Install the coolant filler tank. Refer to INSTALLATION , Coolant Filler Tank .
Install the generator. Refer to INSTALLATION , Generator .
Install the intercooler. Refer to INSTALLATION , Intercooler .
Install the air intake duct and air cleaner case. Refer to INSTALLATION , Air Cleaner Case . Refer to INSTALLATION , Air Intake Duct .
Install the battery to the vehicle, and connect the battery cables.
Lift up the vehicle.
Install the under cover.
Fill engine coolant. Refer to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant .
Charge the A/C system with refrigerant. Refer to PROCEDURE , Refrigerant Charging Procedure .
Install the collector cover.